abstract: Nanostructured zeolites, in particular nanocrystalline zeolites, are of great interest due to their efficient use in conventional catalysis, separations, and emerging applications. Despite the recent advances, fewer than 20 zeolite framework types have been synthesized in the form of nanocrystallites and their scalable synthesis has yet to be developed and understood. Geopolymers, claimed to be “amorphous cousins of zeolites”, are a class of ceramic-like aluminosilicate materials with prominent application in construction due to their unique chemical and mechanical properties. Despite the monolith form, geopolymers are fundamentally nanostructured materials and contain zeolite nanocrystallites. Herein, a new cost-effective and scalable synthesis of various types of nanocrystalline zeolites based on geopolymer chemistry is presented. The study includes the synthesis of highly crystalline discrete nanorods of a CAN zeolite framework structure that had not been achieved hitherto, the exploration of the Na−Al−Si−H2O kinetic phase diagram of hydrogels that gives SOD, CAN and FAU nanocrystalline zeolites, and the discovery of a unique formation mechanism of highly crystalline nanostructured FAU zeolite with intermediate gel products that possess an unprecedented uniform distribution of elements. This study demonstrated the possibility of using high-concentration hydrogels for the synthesis of nanocrystalline zeolites of additional framework structures. Moreover, a comprehensive study on nanostructured FAU zeolites ion-exchanged with Ag+, Zn2+, Cu2+ and Fe2+ for antibacterial applications is presented, which comprises metal ion release kinetics, antibacterial properties, and cytotoxicity. For the first time, superior metal ion release performance was confirmed for the nanostructured zeolites compared to their micron-sized counterparts. The metal ion-exchanged FAU nanostructured zeolites were established as new effective antibacterial materials featuring their unique physiochemical, antibacterial, and cytotoxic properties. / Dissertation/Thesis / Doctoral Dissertation Chemistry 2019

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Zeolite catalysts of three types (H-ZSM-5, Fe-ZSM-5 and H-Beta) were tested in the catalytic co-conversion of rapeseed cake and safflower oil into bio-fuel. This low pressure process was carried out at the temperatures of 350 and 400 °C. The yields and compositions of the product mixtures depended on the catalyst nature and the process temperatures. The produced organic phases consisted mainly of hydrocarbons, fatty acids and nitriles. This mixture possessed improved characteristics (e.g. heating value, water content, density, viscosity, pH) compared with the bio-oils, making possible its application as a bio-fuel. The most effective catalyst, providing the highest yield of organic liquid phase, was the highly acidic/wide-pore H-Beta zeolite. The products obtained on this catalyst demonstrated the highest degree of deoxygenation and the higher HHV (Higher Heating Value). The aqueous liquid phase contained water-soluble carboxylic acids, phenols and heterocyclic compounds.

Indiana University-Purdue University Indianapolis (IUPUI) / Extrusion-based 3D printing is one of the emerging additive manufacturing technologies used for printing a range of materials from metal to ceramics. In this process, the required material is extruded from the extruder in the form of a slurry. Zeolite and MOFs are mainly used for CO2 adsorption in the form of pellets and beads due to their good adsorptive property. Researchers are developing monoliths of Zeolite and MOFs and fabricate them using traditional extrusion and implement them in the gas adsorption applications as an option for beads and pellets by developing a monolithic structure. Previous research on Zeolite 13X and 5A have shown good structural and physical properties in monolith form. In this study, we developed slurry of two molecular sieve Zeolite 3A and 4A monoliths powders, mixing it with bentonite clay, methyl cellulose, and PVA as a binder. The slurry preparation was carried out at room temperature. Once the 3D printed samples are dried at room temperature, a sintering process was performed to increase mechanical strength. To be used in real-time applications, the 3D printed Zeolite sample need to have sufficient mechanical strength. The BET surface area test showed good results for Zeolite 13X compared to available literature. The surface area calculated for 3D printed Zeolite 13X was 767m2/g and available literature showed 498 m2/g for 3D printed Zeolite 13X. The microhardness values of 3D printed Zeolite samples were measured using a Vicker hardness tester. The hardness value of the 3D - printed Zeolite samples increased from 8.3 ± 2 to 12.5 ± 3 HV0.05 for Zeolite 13X, 3.3 ± 1 to 7.3 ± 1 HV0.05 for Zeolite 3A, 4.3 ± 2 to 7.5 ± 2 HV0.05 for Zeolite 4A, 7.4 ± 1 to 14.0 ± 0.5 HV0.05 for Zeolite 5A respectively. The SEM, EDS and XRD analysis was performed for 3D printed samples before and after sintering to evaluate their structural properties. The SEM analysis reveals that all 3D printed Zeolite samples retained their microstructure after slurry preparation and also after the sintering process. The porous nature of 3D printed Zeolite walls was retained after the sintering process. The EDS analysis showed that the composition of 3D printed Zeolite samples remained somewhat similar with minor variation for before and after sintering. The framework structure of Zeolite Type X for Zeolite 13X and Zeolite Type A for Zeolite 3A, 4A, 5A were in good shape after sintering as standard peak intensity points were retained. Zn-MOF74 was synthesized using solvothermal synthesis which is a well-established synthesis process used for the synthesis of MOFs. We also developed slurry for Zn-MOF-74 using bentonite clay and PVA as binders and printed small parts using hand printing.

Hydrocracking is one of the most essential catalytic processes in the oil industry for the conversion of heavy fractions of petroleum (light and heavy vacuum gas oil, demetallized oil) and renewable hydrocarbon feedstocks to high-quality fuels. Hydrocracking relies on a bifunctional catalytic process that combines catalytic cracking and hydrogenation steps. In principle, hydrocracking is aimed to convert heavy and ultraheavy oils with maximum fuel selectivity and minimum formation of light gases and polyaromatic compounds, from this high activity and selectivity of the catalyst, is achieved by finding a good balance between its acidic and hydrogenation properties. For this study, platinum catalyst impregnated on alumina was applied for hydrogenation reaction, whereas cracking function was accomplished by ultrastable Y (USY) zeolite. The central objective of the thesis was to study the fundamental effect of extra framework aluminum (EFAl) species forming with the hydrothermal treatment of USY on hydrocracking of selected model compound – n-hexadecane. Three commercial USY zeolites with different SiO2/Al2O3 ratios were steamed until they reached down to the conversion curve of the reference USY sample physically mixed with 1% Pt supported on alumina in a 1:10 ratio. XRD patterns showed that the crystalline faujasite structure was kept after steaming. In the physisorption of argon, slight changes were observed in surface area and pore volumes which were correlated to the structural collapse of the zeolite framework. Dealumination of the zeolite framework was verified by 27Al MAS NMR. FTIR spectroscopy of pyridine adsorption and TPD of ammonia were employed to investigate the acidity of the samples. From the results, it was found that the concentration of Brønsted acid sites was the main contributor to the activity-acidity relationship in n-hexadecane hydrocracking. To gain more insight into the relationship, samples were subjected to n-hexane cracking. Turnover frequency analysis supported the proposal about hydrocracking reaction and also revealed the chemical influence of EFAl on Brønsted acidity observed in catalytic cracking of hexane.

Tesis por compendio / [ES] El Proyecto de investigación aquí descrito se estructura en dos partes. La primera parte se centra en la investigación fundamental con el objetivo de crear un protocolo para la síntesis de zeolitas. La segunda parte se refiere al diseño, síntesis y caracterización de nuevas zeolitas, particularmente utiles para aplicaciones DeNOx,, pero también podría ser útil para aplicaciones MTO. La investigación fundamental sugiere un Nuevo modelo de preparación de zeolitas utilizando otras zeolitas como simiente. Este proceso se llama transformación zeolita-zeolita o también conversión interzeolita. El alto rendimiento obtenido, la rápida cristalización y la mejor utilización y rendimiento de los materiales de partida se han tenido en cuenta para mejorar el proceso en base a un proyecto de doctorado financiado por una empresa. Este método se ha ilustrado utilizando varias zeolitas como semilla, entre otras FAU y CHA, para la preparación de las dos zeolitas objetivo: AEI y AFX. En la segunda parte, la investigación se centra en el diseño de nuevas zeolitas de poro medio. Se han seleccionado tres zeolitas hipotéticas de una base de datos de 933611 estructuras. Esta selección se ha realizado utilizando descriptores específicamente diseñados en base a la aplicabilidad de estas zeolitas en procesos DeNOx zeolitas. A continuación se han buscado los agentes directores de estructura (ADE) más apropiados, con la ayuda de métodos computacionales, algunos de los cuales se han sintetizado posteriormente. El uso de dichos ADE en el gel de síntesis ha permitido la obtención de una zeolita cuya topología (ERI) ha sido identificada mediante análisis por PXRD, y cuya morfología y tamaño de cristal (particularmente pequeño) la hacen muy adecuada para su uso como catalizador en algunos procesos. El trabajo de síntesis también reveló la aparición de una nueva zeolita de alta densidad, llamada 'paracelsio-K'. Este nuevo material se ha obtenido al explorar el espacio de fases que cristalizan al utilizar 1-methyl-DABCO como ADE. La síntesis de esta zeolita tiene un especial interés porque el ADE no se incorpora en los canales de la zeolita, pero más bien influyendo en la nucleación y cristalización. La caracterización reveló que la composición del material es próxima al mineral microcline, estructuralmente cercano al paracelsio, ambos feldespatos. A diferencia de los feldespatos el paracelsio-K contiene moléculas de agua en su interior (1 molécula por cavidad) y puede describirse como el material más simple de la familia de las zeolitas que contiene cadenas del tipo 'doble-cigüeñal'. Utilizando los elementos topológicos correspondientes a esta estructura es posible generar estructuras zeolíticas ya conocidas, como GIS, APC, MER, PHI, SIV y algunas otras zeolitas hipotéticas. / [CA] El Projecte d'investigació aquí descrit s'estructura en dos parts. La primera part se centra en la investigació fonamental amb l'objectiu de crear un protocol per a la síntesis de zeolites. La segona part es refereix al disseny, síntesis i caracterització de noves zeolites, particularment útils per a aplicacions DeNOx , però també podria ser útil per a aplicacions MTO. La investigació fonamental suggereix un nou model de preparació de zeolites utilitzant altres zeolites com a llavor. Aquest procés s'anomena transformació zeolita-zeolita o també conversió interzeolita. L'alt rendiment obtingut, la ràpida cristal·lització i la millor utilització i rendiment dels materials de partida s'han tingut en compte per millorar el procés en base a un projecte de doctorat finançat per una empresa. Aquest mètode s'ha il·lustrat utilitzant diverses zeolites com a llavor, entre altres FAU i CHA, per a la preparació de les dues zeolites objectiu: AEI i AFX. A la segona part, la investigació se centra en el disseny de noves zeolites de porus mitjà. S'han seleccionat tres zeolites hipotètiques d'una base de dades de 933.611 estructures. Aquesta selecció s'ha realitzat utilitzant descriptors específicament dissenyats sobre la base de l'aplicabilitat d'aquestes zeolites en processos DeNOx zeolites. A continuació s'han buscat els agents directors d'estructura (ADE) més apropiats, amb l'ajuda de mètodes computacionals, alguns dels quals s'han sintetitzat posteriorment. L'ús d'aquests ADE al gel de síntesi ha permès l'obtenció d'una zeolita la topologia (ERI) ha estat identificada mitjançant anàlisi per PXRD, i la morfologia i mida de vidre (particularment petit) la fan molt adequada per al seu ús com a catalitzador en alguns processos. El treball de síntesi també va revelar l'aparició d'una nova zeolita d'alta densitat, anomenada 'paracelsio-K'. Aquest nou material s'ha obtingut a explorar l'espai de fases que cristal·litzen en utilitzar 1-methyl-DABCO com ADE. La síntesi d'aquesta zeolita té un especial interès perquè el ADE no s'incorpora en els canals de la zeolita, però més aviat influint en la nucleació i cristal·lització. La caracterització va revelar que la composició del material és propera al mineral microcline, estructuralment proper al paracelsio, tots dos feldspats. A diferència dels feldspats el paracelsio-K conté molècules d'aigua al seu interior (1 molècula per cavitat) i pot descriure com el material més simple de la família de les zeolites que conté cadenes del tipus 'doble-cigonyal'. Utilitzant els elements topològics corresponents a aquesta estructura és possible generar estructures zeolítiques ja conegudes, com GIS, APC, MER, PHI, SIV i algunes altres zeolites hipotètiques. / [EN] The research project described herein is structured in two parts. The first part is focused on the fundamental research with the aim of creating a toolbox for zeolite preparation. The second part deal with the design, synthesis and characterization of novel zeolites particular useful for DeNOx applications, but could be also useful for MTO applications. The fundamental research is addressing a novel approach of preparing zeolites by using other zeolites as raw materials. This process is known as zeolite-to-zeolite transformation or interzeolite conversion. The high yield obtained, fast crystallization time and the better utilization of the raw materials (e.g. parent zeolite, organic structure directing agent (OSDA)), are important benefits of interzeolite conversion technic, which answer the objectives formulated for an industrial PhD project. The method has been exemplified by using various raw materials as parent zeolites, such as FAU and CHA for the preparation of two target small pore zeolites AEI and AFX. In the second part the focus has been on the design of novel small pore zeolites. Three hypothetical frameworks have been selected by narrowing down a database containing 933611 structures. The selection has been performed by using the general descriptors for the state-of-the-art DeNOx zeolites (e.g. CHA). This was followed by finding suitable OSDAs for the selected frameworks, by using computational methods. The usage of the theoretically predicted OSDAs in synthesis gels made possible the synthesis of a novel high-silica zeolite. PXRD analysis, revealed that the zeolite has the ERI framework topology. The obtained material has a distinct particle morphology and smaller crystallites, which are key parameters for various catalytic processes. The synthesis work revealed also a novel dense zeolite, named K-paracelsian. The new material has been obtained while exploring the phase space using 1-methyl-DABCO as OSDA. The synthesis of this zeolite is especially interesting in the sense that the OSDA is not being incorporated into the zeolite channels, but rather influencing the nucleation and crystallization. Further characterization revealed a material compositionally closely related to the mineral microcline and structurally closely related to the mineral paracelsian, both of which are feldspars. In contrast to the feldspars, K-paracelsian contains intrazeolitic water corresponding to one molecule per cage and can be described as the simplest endmember of a family of dense double-crankshaft zeolite topologies. By applying the identified building principle, a number of known zeolite frameworks (e.g. GIS, APC, MER, PHI, SIV) and hypothetical zeolite topologies can be constructed. / The authors thank Haldor Topsoe A/S and Innovation Fund Denmark for financial support under the Industrial PhD programme (Case no. 1355-0174B). We thank MINECO of Spain for funding (SEV-2016- 0683 and RTI2018-101033-B-100) and ASIC-UPV for the use of computational facilities. We also thank Prof. M. M. J. Treacy for assistance with the Database of Prospective Zeolite Structures. / Boruntea, C. (2020). Design, synthesis and characterization of small-pore zeolites for industrial environmental applications [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/141094 / TESIS / Compendio

Diminishing petroleum resources combined with concerns about global warming and dependence on fossil fuels are leading our society to search for renewable sources of energy. In this respect, lignocellulosic biomass has a tremendous potential as a renewable energy source, once we develop the economical processes converting biomass into useful fuels and chemicals. Catalytic fast pyrolysis (CFP) is a promising technology for production of gasoline range aromatics, including benzene, toluene, and xylenes (BTX), directly from raw solid biomass. In this single step process, solid biomass is fed into a catalytic reactor in which the biomass first thermally decomposes to form pyrolysis vapors. These pyrolysis vapors then enter the zeolite catalysts and are converted into the desired aromatics and olefins along with CO, CO2, H2O, and coke. The major challenge with the CFP process is controlling the complicated homogeneous and heterogeneous reaction chemistry. The focus of this thesis is to study the reaction chemistry, catalyst design, and process development for CFP to advance the CFP technology. To gain a fundamental understanding of the underlying chemistry of the process, we studied the reaction chemistry for CFP of glucose (i.e. biomass model compound). Glucose is thermally decomposed in a few seconds and produce dehydrated products, including anhydrosugars and furans. The dehydrated products then enter into the zeolite catalyst pore where they are converted into aromatics, CO, CO2, H2O and coke. The zeolite catalyzed step is far slower than the initial decomposition step (>2 min). Isotopic labeling studies revealed that the aromatics are formed from random hydrocarbon fragments composed of the dehydrated products. The major competing reaction to aromatic production is the formation of coke. The main coking reaction is the polymerization of the furan intermediates on the catalyst surface. CFP is a shape selective reaction where the product selectivity is related to the zeolite pore size and structure. The shape selectivity of the zeolite catalysts in the CFP of glucose was systematically studied with different zeolites. The aromatic yield is a function of the pore size and internal pore space of the zeolite catalyst. Medium pore zeolites with pore sizes in the range of 5.2 to 5.9 Å and moderate pore intersection size, such as ZSM-5 and ZSM-11 produced the highest aromatic yield and least amount of coke. The kinetic diameter estimation of the aromatic products and the reactants revealed that the majority of these molecules can fit inside the zeolite pores of the medium pore zeolites. The ZSM-5 catalyst, the best catalyst for aromatic production, was modified further to improve its catalytic performance. These modifications include: (1) adjusting the concentration of acid sites inside the zeolites catalyst; (2) incorporation of mesoporosity into the ZSM-5 framework to enhance its diffusion characteristics, and (3) addition of Ga to the ZSM-5. Mesoporous ZSM-5 showed high selectivity for heavier alkylated monoaromatics. Ga promoted ZSM-5 increased the aromatic yield over 40%. A process development unit was designed and built for continuous operation of the CFP process in a pilot scale. The effects of process variables such as temperature, biomass weight hourly space velocity, catalyst to biomass ratio, catalyst static bed height, and fluidization gas velocity were studied to optimize the reactor performance. It was demonstrated that CFP could produce liter quantities of aromatic products directly from solid biomass.

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